IT202000008824A1 - METHOD AND APPARATUS FOR FOAMING SUBSTANTIALLY TWO-DIMENSIONAL OBJECTS - Google Patents

Description

DESCRIPTION FOR INVENTION PATENT

Entitled:? Method and apparatus for foaming substantially two-dimensional objects ?.

BACKGROUND OF THE INVENTION

The present invention relates to a method and an apparatus for conveying in steps, the easy-access opening of foaming masks, and the foaming of substantially two-dimensional objects, i.e. objects with two dimensions prevailing with respect to a third dimension, such as doors. for chillers, panels and other items.

STATE OF THE TECHNIQUE

Various systems are known for foaming substantially flat objects, such as refrigerator doors.

These systems provide for the use of special foaming masks, shaped to contain the doors to be foamed and intended to be conveyed through different operating stations to perform the various phases of cleaning and loading, foaming, polymerization and shape stabilization of the foamed objects, and opening and extraction of finished products.

With specific reference to refrigerator doors, in general, foaming masks are used which are made up of two parts which can be mutually coupled and which each comprise a respective half-mold, intended to accommodate a corresponding half-shell.

The two half-shells, coupled together, respectively define the external and internal cladding of the finished door.

The door generally has a dimension in height greater than the dimension in width, therefore also the foaming mask? characterized by an analogous geometric relationship, i.e. it has a longitudinal dimension greater than a transversal dimension. Often sets of doors are foamed (door for refrigeration compartment and door for freezer compartment, etc.?) And also in this case the foaming mask has a longitudinal extension that is quite greater than the transversal one.

Different technologies are available for conveying the doors to be foamed. According to a first technology, the operation of conveying such doors? carried out by a carousel with a rotating drum, on which the foaming masks are housed, or mold-holder presses, to contain the doors themselves.

The mold-carrying presses are then mounted on the drum carousel and are driven in rotation integrally with the latter.

Once the door half-shells have been loaded onto the respective half-molds, the latter are mutually closed and held tightly by the aforementioned presses.

The drum carousel rotates in steps, stopping to allow each time, in a stationary position, the execution of various operations, such as the extraction of the foamed doors, the cleaning and loading of the two half-molds, and the dispensing of the blend.

As for the dispensing phase, if the mold is closed before injection, a mixing head is approached and inserted, through a hole in the side of the mold, to inject, inside the cavity. defined by the half-shells, the polyurethane mixture intended to constitute the intermediate layer of insulating material of the door.

On the other hand, when the mold is open, the head is moved over one of the half-shells to pour the polyurethane foam. Immediately after dispensing, the two half-shells are mutually coupled closing the respective half-molds. After the injection of the polyurethane mixture, its expansion begins and then the polymerization phase of the foam begins while the drum carousel rotates by successive steps.

Are the pressure values to be countered relevant and what? requires to adopt, for the presses, rather sturdy structures, which affect the complexity? structural system. Moreover, the drum carousel, due to its natural geometric configuration, involves considerable dimensions in all directions and not in a single prevalent direction of development and this, very often, constitutes a not negligible disadvantage.

Another limitation of the carousel system concerns the aspect relating to the cleaning of the half-molds and loading of the half-shells: these operations are not satisfactorily easy and fast but require a certain effort and labor. by the operators.

In particular, access to the half-molds of each foaming mask is not particularly convenient for the operators involved in the operations of extracting the foamed doors, cleaning the half-molds and loading the half-shells of the doors to be foamed.

Another drawback of this system occurs in the event that maintenance is required on a foaming mask or when it is necessary to replace one or more? pairs of half-molds for foaming doors with different geometries. In that circumstance,? it is necessary to stop the whole system by significantly slowing down the capacity? productive, with negative consequences from an economic point of view.

In summary, the carousel system is often not very versatile or even unsuitable for certain applications in which? extremely important to guarantee a high speed? productive and provide operators with the necessary comfort? to efficiently carry out cleaning, loading or replacing the molds.

A second technology for the production of refrigerator doors and the like? based on a conveyor system equipped with a so-called? paternoster? double chain conveyor device.

This conveyor device? formed by two parallel chains and? conformed to support and drag, bound by the chains, a plurality? of unit? mold holders or foaming masks; each foaming mask can contain a pair of semi-molds for foaming a single door or a set of doors for a single refrigerator.

The foaming masks are maintained in horizontal planes along the entire path. In other words, the foaming masks advance while always keeping parallel to themselves and for this purpose rather complex mechanisms are provided for coupling the chain elements with respective drive pinions.

The foaming masks, in a specific area along the path of advancement, are opened to carry out the operations of extracting the foamed doors, cleaning the half-molds and inserting new half-shells to be foamed.

For the opening, one of the two parts that make up each mask is rotated until it assumes an angular position of about 90? or a little more? compared to the other part that remains level. In this way, an operator is allowed access from only one side of the foaming mask.

A system defect of the? Paternoster? ? given by the fact that the aforesaid operations are not satisfactorily easy for the operators due to the particular arrangement of the foaming machines along the advancement path and in particular in the area dedicated to the preparatory operations preliminary to the foaming step.

Furthermore, even in this type of plant, which is rather expensive and structurally complex, in case of maintenance or replacement of the molds? it is necessary to stop the entire production line, with obvious economic losses.

AND? also known the use of a system called a? carousel? which defines a closed horizontal path along which a plurality of of foaming masks, each comprising a lower half-mold and an upper half-mold, mutually hinged along one side.

The upper half-molds are mechanically connected to guides, suitably shaped according to a cam profile: in this way, during the advancement, the upper half-molds receive an opening movement from the aforementioned guides in correspondence with an operating area in which the operations of extracting the newly printed objects, cleaning, loading of new half-shells, dispensing and subsequent closing of the molds are possible. The molds move simultaneously, since they all share the same common driving device.

Although this type of plant can operate continuously, speed is still necessary. very limited progress, due to the complexity? structural and in particular of the mechanical couplings between the molds and the guides and / or parts of the dragging device. Also in this case, the possible need? to intervene for maintenance or to replace one or more? molds requires the shutdown of the entire plant, with consequent downtimes and losses in productivity.

Similarly to the other systems described above, also in this case? an operating area is provided in which the operations of extracting the objects just printed, cleaning, loading of new half-shells, dispensing and subsequent closing of the molds are carried out.

Also for this system there are some following limits: is speed necessary? very limited progress, due to the complexity? structural and in particular of the mechanical couplings between the molds and the guides and / or parts of the dragging device. Also in this case, a necessary intervention for maintenance or replacement of one or more? molds implies the stoppage of the entire plant, with the inevitable machine stoppages that derive from it.

Furthermore, ? to highlight once again a not easy and unsatisfactory accessibility? by the operators to the foaming masks to carry out the cleaning and loading of the half-shells to be foamed.

In particular, for all the types of systems described above? to highlight that the poor ergonomics and the difficulties? access to the open half-molds induce operators to undertake reckless and dangerous operations, for example by climbing completely with their own body on the service area of the systems and on the foaming masks in order to be able to reach, for example, all the most important areas. impervious to complete the cleaning of the half-molds. Obviously, this practice is highly risky for health and safety? of operators.

In the light of what has been described above, there is therefore considerable scope for improvement for the current conveying systems for the foaming of doors, panels and other substantially flat articles.

AIMS OF THE INVENTION

A purpose of the invention? to overcome the limits set out above and to improve the current conveying and foaming systems.

Another purpose? to provide an apparatus and a method capable of making more? cleaning and loading of the foaming masks are quick and easy for operators.

Also, a purpose? to improve and make more? the service area intended for operators is ergonomic, ensuring that the aforementioned operations can be carried out in total safety, while preserving safety. of the operators themselves.

An additional purpose? to provide a solution capable of reducing overall dimensions. Specifically, a purpose? to provide an apparatus which, in addition to being characterized by a high structural and functional simplification, on par? of overall dimensions, allows the housing and conveying of a greater number of foaming masks, in order to process a large number of objects in the unit? of time.

An additional purpose? to provide a more versatile apparatus able to satisfy the current and growing demand from the market which, in the production of refrigerators, requires a diversification of the various models, with variation of aesthetic appearance and geometric shape, dimensions, combination of lower doors and upper, and respective cabinets.

Therefore, we intend to provide a solution that makes it possible to insert in real time, without the need? to stop the production cycle of numerous possible geometric configurations of the foaming half-molds intended for the production of the different geometric shapes of the door.

We therefore intend to provide a solution capable of satisfying the demand for different door models by operating according to the? Just in time? Method. that is? making available the combination of doors for the specific refrigerator model which? in the production line together with various other models to satisfy the sequence of orders coming from the market.

There? ? useful to avoid accumulating stocks of single models in stock.

A purpose ? therefore to offer a solution able to manage in a flexible and optimized way a pi? high number of different forms of door, even different from each other, on the same production line, ensuring at the same time high productivity? and the remarkable ergonomics for the operators, as mentioned above.

BRIEF DESCRIPTION OF THE INVENTION

These and other objects and advantages of the invention are achievable by means of a method and by means of an apparatus as defined in the claims.

Precisely, the apparatus and the method according to the invention considerably facilitate the operator's operations in the service area, making the same operations easier. fast and placing the operators in a position to be able to work in total safety.

Therefore, an easy and ergonomic access to the foaming masks is achieved by the operators.

In the following description, for simplicity? of exposure, the terms? semi-unit? molding? to indicate the two matchable parts that define a single foaming mask.

The semi-units? of molding can be understood as containment elements which comprise respective half-molds shaped to house opposing half-shells intended to generate the faces of a door or other object.

In a possible version, the half-molds can be understood as elements shaped to directly receive the reactive chemical mixture, for the foaming of objects without external half-shells, such as cushions, head-rests or parts of seats for motor vehicles and the like.

Further characteristics and advantages will emerge from the dependent claims, the figures and the following description.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention will be able? be better understood and implemented with reference to the attached drawings, which illustrate an exemplary and non-limiting form of implementation, in which:

Figure 1? a schematic perspective view from above of an apparatus according to the invention;

Figure 2? a diagram of the path of advancement for the foaming masks according to the present invention;

Figure 3? a schematic cross-sectional view of a foaming mask in closed configuration and containing a foamed object;

Figure 4? a front view of the apparatus according to the invention;

Figure 5? a side view of the apparatus according to the invention;

Figure 6? a top view of the apparatus according to the invention;

Figures 7 and 8 are interrupted lateral and perspective views, respectively, of a portion of the apparatus, in particular an upstream portion with respect to a service area for operators in which? provided a transfer device and an opening device for the foaming masks;

Figure 9 shows a portion of the apparatus in which? visible a foaming station and a device for closing the foaming masks;

Figure 10? an enlarged view of one end? of the apparatus, in which a closure device and a device for transferring the foaming masks from an upper path plane to a lower path plane are visible;

Figure 11 shows, according to a perspective view, the extremity? of the apparatus of Figure 10, in which? the foaming station is also visible;

Figure 12? an interrupted and enlarged front view in which? visible a removal station for foamed objects.

DETAILED DESCRIPTION OF THE INVENTION

With reference to the attached Figures,? shown an apparatus 1 for conveying by steps and foaming, with a chemically reactive mixture, of substantially two-dimensional objects 2, that is to say substantially flat objects or having two dimensions prevailing with respect to a third dimension.

The objects may include doors for refrigerators and freezers, walls for display counters, door-lids for chest freezers, parts of walls or insulating coatings for a building or the like, doors and windows for houses and buildings, and other similar objects.

Right away ? specific reference to doors for refrigeration equipment (refrigerators, freezers) equipped with external cladding elements, such as half-shells or shaped panels in plastic, metal, or flat, curved or corrugated plates or sheets, including cladding elements an intermediate thermally insulating layer in polyurethane or phenolic material must be interposed (through the foaming process).

In particular, the refrigerator doors 2 to which specific reference is made, although not limiting, may have an external half-shell in plastic or sheet metal, intended to define the external face during normal use of the door, and a semi internal shell, generally in thermoformed thermoplastic material, intended to define the internal face of the door with respect to the refrigerator compartment associated with it.

The two half-shells are coupled to form a hollow box, possibly provided with a gasket on the perimeter, and between which the foaming operation takes place to generate the intermediate layer in thermally insulating polyurethane or phenolic material.

Do not ? except that the apparatus 1 described below can also operate for the foaming of objects without coating layers or external shells.

The apparatus 1? configured to work through the use of 3 foaming masks - defined by semi-unit? 3A, 3B of molding which can be mutually coupled / uncoupled -conformed to contain the objects 2 to be foamed, and intended to be advanced by steps, through various stations, along a closed feed circuit C, by means of a conveyor device DC. The semi-units? 3A, 3B of molding will be described more? in detail below.

The DC conveyor device? of the type comprising a plurality of of motorized support rollers, arranged transversely with respect to the direction of advancement of the foaming masks 3 along the closed advancement circuit C. However it can? be provided, as an alternative to the motorized rollers, a different one, provided? suitable structural / functional configuration for the DC conveyor device.

Pi? precisely, the closed advancement circuit C comprises a first advancement path P1 (along which the preparation, loading and foaming operations take place) followed by a second advancement path P2 (along which the polymerization and stabilization of shape takes place of the foamed objects 2 enclosed inside the foaming masks 3).

The first feed path P1 lies on a horizontal plane PO and extends along a first feed direction D1 and at least a second mutually transverse direction D2. The DC conveyor device? configured to advance the foaming masks 3 along the entire closed advancement circuit C according to a horizontal arrangement, so that the polymerization and shape stabilization takes place with the two-dimensional objects 2 in a horizontal extended position, (with advantages in terms of homogeneity ? of foaming and polymerization and consequent high qualitative levels of the objects 2 obtained) and maintaining their larger dimensions oriented transversely with respect to the aforementioned first D1 and third D3 directions of advancement.

Thanks to this configuration, a reduction in overall dimensions is also achieved and / or? possible, on par? of overall dimensions, place a greater number of foaming masks 3 along the closed feed circuit (C), at the same time allowing - to the operators (O1, O2, .. On) placed in a special service area Zs, an access easy and ergonomic to the foaming masks (3) from the long sides of the latter.

The second advance path P2 extends, at least partially, along a third direction D3 parallel to the aforementioned first direction D1.

Pi? precisely, the second advancement path P2 extends on a plane P1 located at a lower level than the aforementioned horizontal plane PO. The second P2 progression path? rectilinear and is coplanar and lying on the same vertical plane on which lie an upstream stretch TM and a downstream stretch TM of the first advance path P1.

According to a further possible embodiment, not shown, the second advancement path P2 can? extending on the same horizontal plane PO on which the first advancement path P1 lies so as to advance the foaming masks 3 along an entirely flat, closed loop circuit.

Along the first P1 path of advancement? provided for a ZS service area that includes a support surface for the reception of one or more? foaming masks 3 to be prepared for the foaming process; the ZS service area? configured for positioning in an open configuration that is mutually coplanar of the semi-units? 3A, 3B for molding each mask 3 (opening at 180 ° of the molding half-units 3A, 3B); in the ZS service area, the semi-unit? 3A, 3B of molding advance, in a planar configuration totally open at 180 °, with their larger dimensions oriented longitudinally with respect to the aforesaid second direction D2, so? to be allowed to pi? operators O1, O2, ..On easy access to both semi-units? 3A, 3B molding on both sides A, B of the same service area ZS.

As better visible in Figures 1, 2, 3, the masks 3, in the service ZS, advance along a first portion T1 which extends in the aforementioned second direction D2 of advancement and subsequently advance along a second portion T2 which? orthogonal to the first section T1. The second section T2 is followed by a third section T3 which extends parallel to the aforementioned first section T1 along a direction D2? parallel but opposite to the second direction D2 of advancement.

The apparatus 1 comprises, downstream of the service area ZS - along a stretch TV of the route which extends in the first direction D1 - a foaming station SF arranged for the feeding of a certain quantity of water. of chemically reactive mixture in each foaming mask 3 to obtain the respective object 2.

The SF foaming station comprises one or more? 20 mixing heads, supported by one or more? mobile trolley devices 21 sliding on a support structure 22.

The mixing heads 20 are configured to be able to deliver the reactive mixture both in the mode? ? with the mold closed? is in the mode? ? open mold ?.

The mixing heads 20 can be operated independently of each other and synchronized to deposit the chemically reactive mixture on different areas of a single same cavity. of half-shell or half-mold 10A, 10B or to deposit the chemically reactive mixture on pi? respective and separate cavities provided on each half-shell or half-mold 10A, 10B and intended for the simultaneous foaming of a set of distinct objects 2. The aforementioned set of objects can? for example, it includes a set of doors intended to be associated with pi? respective compartments of the same refrigeration apparatus.

According to a first possible modality? operative, the mixing heads 20 are moved relative to the foaming mask 3 lying with the half-units? open, above the latter, to pay the predetermined amount in a distributed manner. of reactive mixture, thus following an "open mold" foaming operation.

According to this modality? operational, the mixing heads 20 can be operated independently of each other and be synchronized so as to deposit the chemically reactive mixture on different areas of a single same cavity. of the half-shell 12A, 12B or of the half-mold 10A, 10B (in the case of foaming of objects without coating layers or external shells) or to deposit the chemically reactive mixture on more? respective and separate cavities provided on each half-shell 12A, 12B or half-mold 10A, 10B and intended for the simultaneous foaming of a set of distinct objects 2.

In a second possible way? operating, the mixing heads 20 are placed close to and coupled to the foam mask 3 concerned, previously placed in a closed configuration, to inject the quantity inside it. request for reactive mixture. In doing so, it can? be carried out a? foaming operation? with the mold closed ?.

In the vicinity? the SF foaming station? a closing device 9 is provided for mutually coupling the half-units in the closed position? 3A, 3B of molding at the end of the pouring phase of the reactive mixture, carried out in the open mold condition, or before the feeding phase of the reactive mixture in the closed mold condition.

Downstream of the SF foaming station? provided a first transfer device 4 configured to transfer each closed foaming mask 3 in succession, i.e. with the respective half-units? 3A, 3B of molding in mutually coupled configuration, from the first advancement path P1 to the second advancement path P2 located at a lower level, along which the polymerization and shape stabilization of the foamed objects 2 enclosed in the foaming masks 3 takes place.

The apparatus 1 includes, at the end? opposite to the aforementioned first transfer device 4, a second transfer device 5 configured to transfer each closed foaming mask 3 in succession - i.e. with the respective half-units? Mutually coupled molding 3A, 3B - from the second feed path P2 to the first feed path P1.

Both the first transfer device 4 and the second transfer device 5 each comprise a support plane 18 for a foaming mask 3, this support plane 18 being movable from a higher level to a lower level and vice versa and being vertically sliding. along vertical guide posts 19.

The apparatus 1 also comprises - along a stretch TM of upstream path extending in the aforementioned first direction D1 - an opening device 6 configured to open each foaming mask 3 by arranging the respective half-units? 3A, 3B of molding in a mutually coplanar open configuration (opening at 180 °) at the end of the phase of polymerization and shape stabilization of the objects 2.

Each of the aforementioned closing device 9 and opening device 6 comprises two mutually spaced fifth wheel members 16 to engage with the opposite smaller sides of a half unit. 3A of molding to rotate it by 180? around a horizontal axis (YR1, YR2) in correspondence of its major side, to couple / uncouple it from the other semi-unit? 3B molding.

Upstream of the ZS service area,? provided in the apparatus 1 is a removal station WR comprising a gripping device 15 for picking up the foamed objects 2 from the respective foaming masks 3. The gripping device 15 comprises elements 17 of the suction cup type or of the suction type.

In the WR removal station? a conveyor belt 23 is provided for evacuating the finished objects 2 removed from the respective foaming masks 3.

As best shown in Figure 12, the gripper 15? supported by a support element 30 which, by means of suitable motors 31, 32,? movable, with respect to a support structure 33, in the three directions in space. In this way, the gripping device 15 operates to take the foamed doors 2 from the respective open masks 3 to subsequently place them on the aforementioned conveyor belt 23.

The apparatus 1 includes, upstream of the ZS service area, a mold change toilet station arranged to allow the maintenance and / or replacement of the half-molds 10A, 10B, or of the half-units? of molding 3A, 3B.

The mold change station WC comprises a ring-type opening / closing device 16 similarly to that described above for the opening device 6 and the closing device 9.

Thanks to the mold-change toilet station, any need? of the aforementioned maintenance or replacement intervention, does not imply the shutdown of the entire system, thus avoiding the unwanted machine downtime that would result.

The foaming masks 3 are better described below.

How already? anticipated, each mask 3? defined by a pair of semi-units? 3A, 3B of molding which can be mutually coupled / decoupled. Precisely, the semi-units? 3A, 3B of molding of each foaming mask 3 are mutually hinged along a longer side.

Each semi-unit? 3A, 3B of molding comprises a half-mold 10A, 10B mounted, removably, on a reinforcement superstructure 11A, 11B having the function of containing the deformations deriving from the expansion pressure of the foam.

Each half mold 10A, 10B? conformed to receive and contain one or more? respective half-shells 12A, 12B or covering elements intended to define the external surfaces of the corresponding objects 2, in this case doors, and to contain the intermediate layer 13 generated by the foaming process.

The reinforcement superstructures 11A, 11B are suitably sized to effectively counteract the thrusts of the expansion of the reactive mixture and include suitable elements for reciprocal centering and coupling.

According to a version, described and shown here, between each reinforcement superstructure 11A, 11B and the respective half-mold 10A, 10B? interposed a support pallet 14A, 14B, suitable to allow a quick and easy replacement of the half-molds 10A, 10B without having to extract also the superstructures 11A, 11B forming part of the respective foaming mask 3.

Thanks to this configuration, and thanks to the mold change toilet station, the apparatus 1 according to the invention? able to operate a foaming? just-in time? refrigerator doors; in other words, the operations of replacing the half-molds with other geometrically different ones are very quick and easy for the production of doors each time shaped in an aesthetically different way.

The operation of the apparatus 1 just described is briefly described below.

In the service area ZS, the foaming masks 3 to be prepared for the foaming process are arranged with the respective half-units? 3A, 3B of molding lying horizontally, in an open configuration that is mutually coplanar and oriented longitudinally with respect to the first advancement portion T1 (second direction D2) and to the second portion T2 (further direction D2?) Of the first advancement path P1.

Operators can cos? easy access from the two sides A, B of the path to both semi-units? 3A, 3B for molding (from the respective long sides) to carry out the cleaning and positioning operations of the half-shells 12A, 12B to be foamed. Pi? precisely, the first operators O1, O2, can access with ease? to the semi-unit? 3B while the other operators O3, O4 can access easily? to the semi-unit? 3A of each foaming mask 3. The foaming masks 3, thanks to the specific configuration of the conveyor device DC, run in sequence the first section T1, the second section T2 and the third section T3 without ever rotating on themselves, that is to say they translate while keeping parallel to s? same. Thereby ? guaranteed accessibility on the long sides of the masks 3 on both opposite sides A and B of the service area ZS; in particular, the first operators O1, O2 placed on side A, are allowed access to the semi-units? 3B and, subsequently, the other operators O3, O4 placed on side B of the ZS service area, are allowed access to the other semi-units? 3A of each foaming mask 3. In other words, while the operators O1, O2 carry out the required operations on the semi-units? 3B, the other operators O3, O4 complete the operations on the semi-units? 3A of the 3 masks already? previously processed by the above operators O1, O2.

Once the aforementioned preparation and loading operations have been completed, the semi-units? 3A, 3B of molding of each mask 3 are advanced in sequence towards the downstream stretch TV in the direction D1 to reach the foaming station SF.

? it should be noted that the foaming masks 3, during their advancement along the entire closed circuit C, maintain the same orientation, that is to say they advance parallel to s? same; in other words, how already? mentioned above, the foaming masks 3 are translated but not rotated.

Thanks to the specific configuration of the DC conveyor device and the? T? of the first advancement path P1, at the same time one achieves the double advantage of a reduction in the overall dimensions of the apparatus 1 (and / or the advantage of making it possible to position a greater number of masks 3 in the advancement circuit C at par? of overall dimensions) and the advantage of greater ergonomics and easier access on the long sides of the foaming masks 3 in the service area ZS.

One at a time, each foaming mask 3 reaches the foaming station SF in which the phase of dispensing the reactive mixture takes place in the mode? with open mold or in mode? with closed mold.

In the case of foaming in? Open mold ?, the corresponding semi-units? 3A, 3B of molding remain open to receive the quantity from above. dosed of reactive mixture by the mixing heads 20, after which? they are immediately re-coupled by the closing device 9.

Otherwise, if you operate in? with? closed mold ?, the closing device 9 preliminarily closes the half-units? 3A, 3B of molding, making it possible subsequently for the mixing heads 20 to introduce the reactive mixture inside the closed foaming mask 3.

In any case, the closure device 9 acts to rotate by 180? a semi-unit? 3A of molding around the horizontal axis YR1, in correspondence with one of its longer sides, to superimpose it on the other half-unit? 3B molding cos? to close the corresponding foaming mask 3.

At the end of the dispensing of the mixture by the mixing heads 20, the conveying device DC further advances the skimming mask 3 in question, making it reach the first transfer device 4 which lowers it, transferring it from the first feed path P1 to the second advancement path P2 placed below.

At this point, the conveying device DC advances the aforementioned closed foaming mask 3 along the entire second advance path P2 along which the polymerization and shape stabilization of the foamed doors 2 enclosed in said foaming mask 3 takes place.

Arrived at the extremity? opposite of the second path P2 of advancement, the foaming mask 3 is raised by the second transfer device 5 to reach the end? upstream of the TM section of advancement.

The conveying device DC advances the foaming mask 3 towards the opening device 6 which uncouples the half-unit? 3A from the semi-unit? 3B, opening cos? the foaming mask 3 to allow the extraction of the foamed door (s) 2. The opening device 6? operated to open one after the other, each foaming mask 3 rotating by 180? a respective semi-unit? 3A for molding around a further horizontal axis YR2, in correspondence with one of its longer sides, to separate it from the other half-unit? 3B of molding thus allowing the extraction of the objects 2 already? foamed.

The foam mask 3 in open configuration? advanced into the removal station WR, where the gripping device 15 removes the gates 2 obtained.

At this point, the semi-units? 3A, 3B of molding, lying horizontally in a coplanar open configuration (opening at 180?), Reach the service area ZS, in which the operators O1, .. N can again carry out the cleaning, preparation and loading of the half-shells. 12A, 12B to be sent to the next foaming phase.

In the mold-change toilet station, maintenance or replacement of one or more can take place, if required. 3 foaming masks or parts of them, without necessarily stopping the whole plant, thus avoiding? unwanted downtimes.

Do not ? excluded the possibility? to provide in the ZS service area, instead? human operators, one or more? robotic means configured to carry out in a fully automated manner the following cleaning and preparation operations of the foaming masks 3 and loading operations of the half-shells 12A, 12B.

As can be seen from what has been described, the apparatus 1 and the relative method allow to achieve the purposes stated above which include:

- greater ease? and ergonomics of access by operators to the foaming masks in the ZS service area,

- higher level of security and favorable conditions for safety of the operators, - general reduction of the overall dimensions or increase of the reception capacity for the foaming masks in parity? dimensions, with a consequent increase in productivity,

- high structural and functional simplification,

- greater versatility? operational in production, with particular reference to diversification in real time, the production of doors or other objects of different geometric shapes and sizes from time to time, thanks to the possibility? to instantly replace the half-molds of one or more? masks without necessarily having to stop the operation of the apparatus 1.

AND? It is possible to configure and dimension the apparatus 1 as desired according to the dimensions / types of objects to be processed and variants and / or additions to what is described above and illustrated in the attached drawings are possible.

Claims (34)

CLAIMS 1. Method for foaming substantially two-dimensional objects (2) with a chemically reactive mixture, comprising the steps of: a) provide for one or more? foaming masks (3) for the respective objects (2) to be foamed, intended to advance along a closed feed circuit (C), in which each foaming mask (3)? defined by a pair of semi-units? (3A, 3B) of molding that can be mutually coupled / decoupled, b) defining, for said closed advancement path (C), a first advancement path (P1) followed by a second advancement path (P2), in which said first advancement path (P1) lies on a plane (PO) horizontal and extends along a first direction (D1) of advancement and at least a second direction (D2) mutually transverse, and in which said second advancement path (P2) extends at least partially along a third direction (D3) parallel to said first direction (D1), c) positioning, in a service area (ZS) provided along said first path (P1) of advancement and extending parallel to said at least one second direction (D2), one or more? foaming masks (3) to prepare for the foaming process and arrange the respective half-units? (3A, 3B) for molding each foaming mask (3) in an open configuration that is mutually coplanar and with its larger dimensions oriented longitudinally with respect to said second direction (D2), so? to be allowed to pi? operators (O1, O2, .. On) easy access to both semi-units? (3A, 3B) molding on both sides (A, B) of said service area (ZS), d) complete on said semi-units? (3A, 3B) of molding, in said service area (ZS), the preparation and loading operations preliminary to a foaming step, e) advance the semi-units in sequence? (3A, 3B) of molding each foaming mask (3) towards a foaming station (SF) and starting a feeding phase of a certain quantity. of chemically reactive mixture to obtain the respective object (2), f) transfer in succession each foaming mask (3), with the respective half-units? (3A, 3B) of molding in mutually coupled configurations, from said first feed path (P1) to said second feed path (P2), and g) further advance the foaming masks (3) in closed configuration along said second advance path (P2) to allow polymerization and shape stabilization of the foamed objects (2) enclosed within them, h) transferring, one after the other, each foaming mask (3) from said second advance path (P2) to said first advance path (P1) and i) opening each foaming mask (3) to remove the foaming mask (3). object (2) already? foamed, arranging the respective semi-units? (3A, 3B) of molding in an open mutually coplanar configuration, and, once the foamed object (2) has been extracted, j) advancing the semi-units in succession. (3A, 3B) of open molding of each foaming mask (3) towards said service area (ZS), maintaining the same orientation for said half-units? (3A, 3B) of molding along at least said first feed path (P1) and, k) while advancing along said service zone (ZS), carry out new cleaning, preparation and loading operations on each open foaming mask (3), preliminary to the subsequent foaming step. Method according to claim 1, wherein said second advancement path (P2) extends, at least partially along said third (D3) direction, on a plane (PI) located at a lower level than said horizontal plane (PO) . Method according to claim 1, wherein said second advancement path (P2) extends on the same horizontal plane (PO) on which said first advancement path (P1) lies. Method according to claim 1 or 2, wherein said foaming masks (3) advance along the entire closed feed circuit (C) in a horizontal position, so that the polymerization and shape stabilization takes place with the objects (2) two-dimensional in a horizontal extended position and keeping their larger dimensions transversely oriented with respect to said first (D1) and third (D3) directions of advancement so? to reduce the overall dimensions and / or allow, at par? of overall dimensions, the positioning of pi? foaming masks (3) along said closed advancement circuit (C), at the same time allowing the operators (O1, O2, .. On) placed in said service area (Zs) easy and ergonomic access to the masks ( 3) of foaming through the long sides of the latter. Method according to any one of the preceding claims, wherein the semi-units? (3A, 3B) of molding of each foaming mask (3), in a totally open condition and mutually coplanar at 180 °, advance, in said service area (ZS), along a first section (T1) in said second direction ( D2) of advancement, subsequently along a second section (T2) orthogonally to said first section (T1) and, subsequently, along a third section (T3) parallel to said first section (T1) and in a parallel direction (D2?) but opposite to said second direction (D2) of advancement. 6. Method according to claim 5, wherein said foaming masks (3) advance, in said service area (ZS), to allow access to half-unit along said first stretch (T1). (3B) of the masks (3) and allow, subsequently, along said third section (T3), access to the other semi-units? (3A) of the corresponding foaming masks (3). 7. Method according to claim 6, wherein said foaming masks (3), before traveling along said first portion (T1) advance along an upstream portion (TM) in said first direction (D1) to allow the opening operation and extraction of the foamed object (2) and in which said foaming masks (3), after having covered said third stretch (T3), advance along a downstream stretch (TV) along said first direction (D1) to undergo the phase feeding of said reactive mixture. 8. Method according to claim 7 when claim 5 depends on claim 1 or 2 or 4, wherein said second advancement path (P2) extends straight, said second advancement path (P2), said portion (TM) upstream and said downstream stretch (TV) being mutually aligned vertically, coplanar and lying on the same vertical plane. Method according to claim 8, wherein? provided for positioning said foaming masks (3) in a foaming station (SF) placed along said downstream stretch (TV) and? expected to feed a certain amount? of chemically reactive mixture inside each foaming mask (3) to obtain the respective object (2). Method according to any one of the preceding claims, in which the step of feeding the aforesaid quantity? of chemically reactive mixture occurs after having previously mutually closed each pair of semi-units? (3A, 3B) of molding, in such a way as to perform a? Foaming operation in a? Closed mold? Condition. Method according to any one of claims 1 to 9, wherein said feeding step, carried out in an? Open mold? Condition, provides for pouring said quantity? of chemically reactive mixture on one of the two semi-units? (3A, 3B) of molding arranged in an open coplanar configuration and, at the end of the pouring of said quantity,? reciprocal closure of the two semi-units envisaged? (3A, 3B) of molding. Method according to any one of the preceding claims, wherein, downstream of said service area (ZS) and before advancing along the second advancement path (P2),? expected to rotate 180? a semi-unit? (3A) of molding around a horizontal axis (YR1), in correspondence of its longest side, to superimpose it on the other semi-unit? (3B) of molding cos? to close the corresponding foaming mask (3) immediately after the pouring of the reactive mixture in modality? with the mold open or before feeding the reactive mixture in mode? with closed mold. Method according to claim 2, or according to any one of claims 4 to 12 when dependent on claim 2, in which, after the feeding step of the reactive mixture, each foaming mask (3) is lowered, by means of a device ( 4) of transfer, from said first advancement path (P1) to said second advancement path (P2) and, at the end of the polymerization and shape stabilization step having along said second advancement path (P2), each mask (3 ) of foaming is raised, by means of a further transfer device (5), to be returned to said first advancement path (P1), being subsequently provided, upstream of said service area (ZS), to open one after the other , each foaming mask (3) rotating by 180? a respective semi-unit? (3A) of molding around a further horizontal axis (YR2), in correspondence of its longer side, to separate it from the other half-unit? (3B) of molding cos? to open the corresponding foam mask (3) and allow the extraction of the objects (2) already? foamed. Method according to any one of the preceding claims, wherein at the end of the polymerization and shape stabilization step of the foamed objects (2), upstream of said service area (ZS),? envisaged to take, by means of a suction gripping device (15) or equivalent, the foamed objects (2) from the respective foaming masks (3) and in which? foreseen, in a mold-change station (WC), a possible replacement of one or more? masks (3) of foaming or of one or more? of these semi-units? (3A, 3B) or parts thereof, without having to stop the advancement and process of the remaining foaming masks (3) along the closed advancement circuit (C). Method according to any one of the preceding claims, wherein each half-unit? (3A, 3B) of molding comprises a half-mold (10A, 10B) mounted, removably, on a reinforcement superstructure (11A, 11B), in which, in said service area (ZS)? expected to house in each half-mold (10A, 10B) one or more? respective half-shells (12A, 12B) or covering elements intended to define the external surfaces of the corresponding objects (2) and / or inserts and to contain the intermediate layer (13) generated by the foaming process. Method according to claim 15, wherein? foreseen to interpose between each reinforcement superstructure (11A, 11B) and the respective half-mold (10A, 10B) a support pallet (14A, 14B), which allows a quick and easy replacement of the half-molds (10A, 10B) without having to extract also the reinforcement superstructures (11A, 11B) which are part of the foaming mask (3). Method according to any one of the preceding claims, wherein said mixture? a polyurethane or phenolic mixture and in which said objects (2) include: refrigerator doors and refrigeration equipment in general, equipped with external shells, cushions or parts of car seats, walls for a counter-display, parts of walls or coverings insulators for a building, panels and other articles having two main dimensions with respect to a third dimension without or equipped with external cladding elements in plastic, metal, or flat, curved, corrugated or shaped plates or sheets as desired. 18. Apparatus (1) for foaming substantially two-dimensional objects (2) with a chemically reactive mixture, comprising: - one or more? foaming masks (3) for the respective objects (2) to be foamed, each foaming mask (3) being defined by a pair of semi-units (3A, 3B) of molding that can be mutually coupled / decoupled, - a conveyor device (DC) configured to move said one or more? foaming masks (3) along a closed advancement circuit (C) which comprises a first advancement path (P1) and a second advancement path (P2) in which said first advancement path (P1) lies on a plane (PO ) horizontal and extends along a first direction (D1) of advancement and at least a second direction (D2) mutually transverse, and in which said second advancement path (P2) extends at least partially along a third direction (D3) parallel to said first direction (D1), - a service area (ZS), placed along said first path (P1) of advancement and extending parallel to said at least one second direction (D2), for the reception of one or more? foaming masks (3) to be prepared for the foaming process, said service zone (ZS) being configured for the positioning of the semi-units? (3A, 3B) of molding in an open configuration that is mutually coplanar and with its larger dimensions oriented longitudinally with respect to said second direction (D2), so? to be allowed to pi? operators (O1, O2, ..On) easy access to both semi-units? (3A, 3B) molding on both sides (A, B) of said service area (ZS), - a foaming station (SF) for feeding a certain quantity of chemically reactive mixture in each foaming mask (3) to obtain the respective object (2), - a first transfer device (4) configured to transfer each foaming mask (3) in succession, with the respective half-units? (3A, 3B) of molding in mutually coupled configuration, from said first advancement path (P1) to said second advancement path (P2) along which polymerization and shape stabilization of the foamed objects (2) enclosed inside takes place foaming masks (3), - a second transfer device (5), placed at the end? opposite to said first transfer device (4) and configured to transfer each foaming mask (3) in succession from said second advance path (P2) to said first advance path (P1), - an opening device (6) configured to open each foaming mask (3) by arranging the respective half-units? (3A, 3B) of molding in a mutually coplanar open configuration at the end of the polymerization and shape stabilization step of the objects (2), and - a removal station (WR) comprising a gripping device (15) for removing the foamed objects (2) from the respective foaming masks (3). 19. Apparatus according to the preceding claim, further comprising, in proximity? of said foaming station (SF), a closing device (9) for mutually coupling in the closed position the half-units? (3A, 3B) of molding at the end of the pouring phase of the reactive mixture, carried out in the open mold condition, or before the feeding phase of the reactive mixture in the closed mold condition. 20. Apparatus according to claim 18 or 19, further comprising a mold-changing station (WC) arranged to allow maintenance and / or replacement of one or more? masks (3) of foaming or of one or more? semi-unit? (3A, 3B) of molding or parts thereof without having to stop the advancement and process of the remaining foaming masks (3) along the closed advancement circuit (C). 21. Apparatus according to claim 20 when dependent on claim 19, wherein said mold-changing station (WC) and each of said closing device (9) and opening device (6) comprise two reciprocally rotating elements (16) spaced apart to engage with the smaller opposite sides of a semi-unit? (3A) of molding to rotate it 180? around a horizontal axis (YR1, YR2) in correspondence of its major side, to couple / uncouple it from the other semi-unit? (3B) of molding. 22. Apparatus according to any one of claims 18 to 21, wherein said conveyor device (DC)? configured to advance said foaming masks (3) along said second advance path (P2) which extends - at least partially along said third (D3) direction - on a plane (PI) located at a lower level than said plane (PO ) horizontal on which said first advancement path (P1) lies. 23. Apparatus according to any one of claims 18 to 21, wherein said conveyor device (DC)? configured to advance said foaming masks (3) along said second advance path (P2) which extends on the same horizontal plane (PO) on which said first advance path (P1) lies. Apparatus according to any one of claims 18 to 23, wherein said conveyor device (DC)? configured to advance said foaming masks (3) along the entire closed advancement circuit (C) according to a horizontal arrangement, so that the polymerization and shape stabilization takes place with the two-dimensional objects (2) in a horizontal extended position and maintaining its larger dimensions oriented transversely with respect to said first (D1) and third (D3) directions of advancement cos? to reduce the overall dimensions and / or allow, at par? of overall dimensions, the positioning of pi? foaming masks (3) along said closed advancement circuit (C), at the same time allowing the operators (O1, O2, .. On) placed in said service area (Zs) easy and ergonomic access to the masks ( 3) of foaming through the long sides of the latter. 25. Apparatus according to any one of claims 18 to 24, wherein said conveyor device (DC)? shaped in such a way as to advance in said service area (ZS) the semi-units? (3A, 3B) for molding each foaming mask (3), in a totally open and mutually coplanar condition, along a first section (T1) in said second direction (D2) of advancement, subsequently along a second section (T2) orthogonally to said first section (T1) and, subsequently, along a third section (T3) parallel to said first section (T1) and in a direction (D2?) parallel to but opposite to said second direction (D2) of advancement, said zone (ZS) of service, extending in such a way as to allow access to semi-unit? (3B) of the masks (3) and allow, subsequently, along said third section (T3), access to the other semi-units? (3A) of the corresponding foaming masks (3). 26. Apparatus according to claim 18, or according to any of claims 18 to 22, or according to claim 24, or according to claim 25 when dependent on any of claims 18 to 21 or claim 24, wherein said device -conveyor (DC)? configured so as to advance said foaming masks (3) - upstream of said service area (ZS) - along an upstream stretch (TM) in said first direction (D1) to allow the opening and extraction of the foamed object (2) and so as to advance said foaming masks (3) - downstream of said service area (ZS) - along a downstream stretch (TV) in said first direction (D1) where? positioned said foaming station (SF) to carry out the feeding phase of said reactive mixture, and in which said second advance path (P2) extends straight, said second advance path (P2), said segment (TM) upstream and said stretch (TV) downstream are mutually aligned vertically, coplanar and lying on the same vertical plane. 27. Apparatus according to any one of claims 18 to 26, wherein said gripping device (15) provided in said removal station (WR) comprises elements (17) of the suction cup or suction type. 28. Apparatus according to any one of claims 18 to 27, wherein said conveyor device (DC) comprises a plurality of products. of motorized support rollers, arranged transversely with respect to the direction of advancement of the foaming masks (3) along the closed advancement circuit (C). 29. Apparatus according to any one of claims 18 to 28, wherein each of said first transfer device (4) and second transfer device (5) comprise a support plane (18) for a foaming mask (3), said support surface (18) being movable from a higher level to a lower level and vice versa and being vertically sliding along vertical guide uprights (19). 30. Apparatus according to any one of claims 18 to 29, wherein the half-units are (3A, 3B) of molding of each foaming mask (3) are mutually hinged along a major side, and in which each half-unit? (3A, 3B) of molding comprises a mold half (10A, 10B) removably mounted on a reinforcing superstructure (11A, 11B), each mold half (10A, 10B) being adapted to receive and contain one or more ? respective half-shells (12A, 12B) or covering elements intended to define the external surfaces of the corresponding objects (2) and to contain the intermediate layer (13) generated by the foaming process. 31. Apparatus according to claim 30, wherein between each reinforcing superstructure (11A, 11B) and the respective half-mold (10A, 10B)? interposed a support pallet (14A, 14B), suitable to allow a quick and easy replacement of the half-molds (10A, 10B) without having to extract also the superstructures (11A, 11B) forming part of the respective foaming mask (3). 32. Apparatus according to any one of claims 18 to 31, wherein said foaming station (SF) comprises one or more? mixing heads (20), supported by a mobile trolley device (21) sliding on a support structure (22), said mixing heads (20) being configured to be able to deliver the reactive mixture in both modality. ? with the mold closed? is in the mode? ? open mold ?. 33. Apparatus according to claim 32, in which said mixing heads (20) are operated independently from each other and synchronized to deposit the chemically reactive mixture on different areas of a single same cavity. of half-shell or half-mold (10A, 10B) or to deposit the chemically reactive mixture on pi? respective and separate cavities provided on each half-shell or half-mold (10A, 10B) and intended for the simultaneous foaming of a set of distinct objects (2). 34. Apparatus according to any one of claims 18 to 33, wherein in said removal station (WR)? a conveyor belt (23) is provided for the evacuation of the finished objects (2) removed from the respective foaming masks (3).